Automated Lubrication System Installation/Operator Instructions Caterpillar Medium Sized Wheel Loader – Cat 980G 1
Contents Pages Introduction------------------------------------------------------------------------------------------ 3 Preparation/Installation Overview ------------------------------------------------------------ 4 Bill of Materials ------------------------------------------------------------------------------------- 5 Component Glossary ----------------------------------------------------------------------------- 6-10 System Operation-----------------------------------------------------------------------
Introduction Thank you for purchasing the Quicklub® On Board Grease System for your Caterpillar medium sized wheel loader. The system has been designed to increase the component life and overall productivity of your equipment, while reducing labor costs related to the traditional method of point-by-point manual lubrication. The system consists of the Quicklub® progressive metering valves that positively displace and meter precise amounts up to N.L.G.I. #2 shop grease down to -13°F temperature.
Preparation/Installation Overview The following steps will assist the installer with a systematic approach for installing the Quicklub Automated lube system on the wheel loader. By following the steps outlined, a successful installation will be achieved and will increase the service life of all pins and bearings connected to the lube system.
Bill of Materials Part Number Description 5045 Zerk Fitting 5527 1/4-28 Grease fitting 10181 1/8" NPT Adapter 10461 Reducing bushing 13129 1/8" NPT 90 degree adapter 14054 Bulkhead connector 14562 Two Station Anchor Block 14570 One Station Anchor Block 20028 1/8" NPT 45 degree adapter 20029 1/8" NPT 90 degree adapter 20031 1/8" NPT 90 degree adapter (short) 51055 Lock Nut for bulkhead connector 66872 Self tapping screw 67448 Street Tee 94822 * 8 Liter 203 style pump (Monitored) 94824 8 Liter 203 style pump
QUICKLUB COMPONENT GLOSSARY PART NUMBER (LINCOLN) and DESCRIPTION 234-13188-3 - 7-Meter Proximity Switch... 20029 - 1/8" NPT 90\U+00B0 Adapter 20031 - 1/8" NPT 90\U+00B0 Adapter... 13129 - 1/8" NPT 90\U+00B0 Adapter 649-29548-1 -SSV-D Divider Block SSV-12 with Indicator Pin... 649-29547-1 -SSV-D Divider Block SSV-10 with Indicator Pin... 649-29550-1 -SSV-D Divider Block SSV-6 with Indicator Pin (1 & 2 Single)...
QUICKLUB COMPONENT GLOSSARY PART NUMBER (LINCOLN) and DESCRIPTION 20028 - 1/8" NPT 45 Adapter... 10461 - Reducer Bushing... 272598 -Spring coil (25 Feet)... 432-24313-1 -Protecting Cap for Push-in Type Fitting... 241484 -Push Button Light Kit... 249850 - 12mm Stand-off... 241289 - 1/8" NPT Swedge on hose stud... 249848 - Grade 8 -12mm Mounting bracket bolt... 14570 - One Station anchor block (junction block)... 14562 - Two Station anchor block (junction block)...
QUICKLUB COMPONENT GLOSSARY PART NUMBER (LINCOLN) and DESCRIPTION 249520 - Mounting bracket assembly... 246002 - 1/8" NPT field installable hose coupling... 5045 - Straight leak-proof grease fitting... 249209 - Grade 8 - 12mm Mounting bracket bolt... 272394 - Hose stud, 90°... 272401 - Hose stud, straight... 272427 - Threaded sleeve... 272658 - Valve outlet fitting... 241288 - 1/8" Grease filled high pressure hose (40 ft. coil)...
QUICKLUB COMPONENT GLOSSARY PART NUMBER (LINCOLN) and DESCRIPTION 94822 94824 644-40827-1 - 203 8 Liter Pump, 24 Volt / 2 Amp Monitored - 203 8 Liter Pump, 24 Volt / 2 Amp Non-Monitored - 203 8 Liter Pump, 24 Volt / 2 Amp Data Logger 252807 - Divider valve mounting block... 303-16118-1 303-16119-1 303-16120-1 303-16121-1 303-16122-1 303-16124-1 303-16126-1 -Metering Adjustment Screw (.0049 cu in)... -Metering Adjustment Screw (.0085 cu in)... -Metering Adjustment Screw (.012 cu in)...
QUICKLUB COMPONENT GLOSSARY PART NUMBER (LINCOLN) and DESCRIPTION 249987 - Grade 8 - 6mm valve mounting bolt... 67448 - Male run tee... 303-17499-3 - Valve closure plug for Black divider valves... 242125 - Plastic Grease fitting cap... 241054 - Nylon Ties (100 count poly bag) 7" Length... 241110 - Feed Line Bundling Spiral Wrap (10ft.) ... 10181 - 1/8" Straight adapter. 66872 - Self Tapping Screw...
System Operation The key components of the Quicklub system are: 1. Pump with Integrated Timer 2. Divider valve network consisting of a Primary Valve and Secondary Valves with attached Cycle Indicator Pin. 3. A lubrication event is initiated by actuating the pump via the Integrated Timer based on a preset “pause time” or time between lubrication events. 4. The Pump dispenses lubricant to the primary divider valve 5. The Primary Valve distributes the lubricant to the secondary valves 6.
Divider Valve Operation At the heart of every Quicklub System is the metering valve or progressive distributor block, designed to positively meter the input of lubricant (oil up to NLGI #2 greases) out to the connected number of lubrication points irrespective of distance and back pressure. The inlet passageway is connected to all piston chambers at all times with only one piston free to move at any one time.
Cross-porting (Divider Valve) Installing a closure plug in one or more outlets may combine outputs from adjacent outlets. Lubricant from a plugged outlet is redirected to the next adjacent outlet in descending numerical order. Outlets 1 and 2 must not be plugged since they have no cross-port passage to the next adjacent outlet (SSV valves only). In figure 5 outlets 5 and 3 are cross-ported and directed through outlet 1. In this example, outlet 1 will dispense three times as much lubricant as outlet 7.
Guarding The dog-bone and boom guarding used in this manual are from Target Medal Systems. Guarding can also be fabricated using angle iron or c-channel for the high impact zones. Dog-bone guarding from Target Medal Systems Boom guarding from Target Medal Systems It is recommended that all lines be protected with spiral wrap for protection. Various sizes of nylon protective sleeving can be found at a Parker distributor (see below).
Welding 14562 double inlet junction block 14570 single inlet junction block Studs – not included in bill of materials All welding should be completed prior to beginning the line routing. Component locations can be found throughout this installation manual. Note: Ensure that the battery is disconnected prior to welding.
System Schematic 16
Installation Details Left Frame Valve Mount the left frame valve below the 8 outlet remote manifold block on the left hand side of the machine.
Left Frame Valve Detail 18
Left Boom Hinge (6) Left Lift Cylinder Rod End (8) Left Bucket Cylinder Pivot (4) Right Bucket Cylinder Pivot (3) Right Boom Hinge (5) Right Lift Cylinder Rod End (7) Right Steering Cylinder Rod End (9) Right Boom Cylinder Pivot (11) Valve outlet numbers are in (parenthesis) 19
Note the use of P-Clamps (part #249913) to secure top center pivot Top Center Pivot (1) Left Steering Cylinder Rod End (10) Valve outlet numbers are in (parenthesis) Left Boom Cylinder Pivot (12) Note the use of P-Clamp (part #249913) to secure left boom cylinder pivot line 20 Drive Shaft Pillow Block (2)
Rear Frame Valve Primary Valve Left Frame Valve Rear Frame Valve 21
Rear Frame Valve Detail 22
Front and Rear Oscillator Bearings (3 & 4) Valve outlet numbers in (parenthesis) Right Steering Cylinder (6) Left Steering Cylinder (5) Remove 1 piston closure screw from the rear valve and insert proximity switch (part # 234-13188-3) in the piston opening. Route the prox. switch cord back to the pump. (Monitored and Data Logger pumps only – part #’s 94822 and 644-40827-1 respectfully) See pump section of this manual for cycle rate info.
Front Valve 24
Front Valve Detail 25
Note P-Clamp (part #249913) locations and line routing Bucket Pins Guarding for bucket pin Bucket pin (9 & 10) line routing Mount the guarding using weld studs for ease of removal if field repairs are necessary.
Run a short hose to the bucket pin lube point. Weld a single inlet junction block (part #14570) at the end of the guarding. Grind off a small amount of the area surrounding the lube point to ensure that the inlet fittings keep a low profile to the machine. Swedge-on hose studs (241289) are used for the bucket pins for added durability and to ensure a low profile.
Bucket Cylinder Rod Ends Line routing and weld stud placement for bucket cylinder rod ends (7 & 8).
Front and Rear Bucket Link Part #249853 (P-Clamp) Line routing and weld stand-off placement for front and rear bucket links (1, 2, 3 & 4).
Weld a double inlet junction block to the back of the bell crank as shown Line routing and guarding for bucket links 30 Notch out the guarding for the rear bucket link line
Bell Crank Part #249853 Right bell crank line routing.
Primary Valve Rear Frame Valve Primary Valve 32
Primary Valve Detail 33
Supply Line Routing from Primary Valve Front supply line Top center pivot line Route left frame valve and front valve supply lines with existing hydraulic lines across machine pivot.
Pump P-Clamps (part #270931) and self tapping screws (part #66872) Pump Location Route supply line, proximity switch cord, electrical power cord, and remote fill line under cab to middle of machine Remote fill line Drill a hole through this bracket and install the bulkhead connector with grease fitting (part #’s 14054, 51055, & 5527) 35
Install the pushbutton on the face of the dashboard (monitored and data logger pumps only) The cycle rate of the rear valve (location of proximity switch) is approximately 18 minutes. It is recommended that the on time be set for 18 minutes (red dial set to 9) on non-monitored pumps. The off time should be adjusted based on the operating conditions of the wheel loader.
ELECTRICAL CONNECTIONS (Non-Monitored Pump) Connect black power cord as follows: Red wire connects to 8amp fuse then to battery (+) hot. White wire connects to battery (-) ground. Blue wire connects to 8 amp fuse, to ignition switch, then to battery (+) switched. TIMER OPERATION The off timer begins accumulating time when the ignition switch closes. When the off timer reaches the preset value the pump will turn on. The pump remains activated for the period of time that is preset on the ON timer.
Timer Setting (Non-Monitored Pump) 1. The LED marked “battery” lights when power is applied to the PC board. 2. The LED marked “motor” lights when pumping lubricant. 3. Depressing pushbutton for 2 seconds will initiate a manual lube event. 4. Off timer rotary switch, can be adjusted to 15 values, (do not set to “0” ) 5. On time rotary switch, can be adjusted to 15 values, (do not use “0” ) IMPORTANT: Do not use the zero position located on the ON or Off timer switch.
ELECTRICAL CONNECTIONS (Monitored Pump) Connect black power cord as follows: Red wire connects to 8amp fuse then to battery (+) switched, and to “P” terminal on pushbutton. Brown wire connects to battery (-) ground. White wire connects to switch terminal on pushbutton (opposite terminal connects to battery (-) ground). Yellow wire connects to “N” terminal on pushbutton. TIMER OPERATION The off timer begins accumulating time when the ignition switch closes.
Timer Operation (Monitored Pump) 1. The LED lights when power is applied to the PC board. 2. Off timer rotary switch, can be adjusted to 15 values, (do not set to “0”) 3. The LED lights when pumping lubricant. 4. Depressing pushbutton for 2 seconds will initiate a manual lube event. IMPORTANT: Do not use the zero position located on the ON or Off timer switch. Note Factory Timer Settings: Off-Time Switch Setting = 6 (24 min.
System Start-up The following checklist has been developed as an aid in verifying proper installation and operation of the Quicklub Onboard Grease System. By completing the steps outlined below, the operational readiness of the system and resulting extension of the component life of all points connected to the system will be insured. • Apply grease gun (manual or pneumatic) to the grease fitting located on the Primary valve and each secondary valve inlet.
Daily Walk-Around Inspection The Lincoln Industrial Quicklub automated lube system components are designed, engineered, manufactured and assembled to the highest or quality standards. This lube system requires little or nor maintenance, however, to ensure maximum reliability and to realize maximum service life of all components, it is highly recommended that a daily walk-around inspection be performed. The daily walk-around inspection should include the following: • Observe lubricant level in reservoir.
Troubleshooting Locating Blockage in Lincoln Quicklub® Systems Description In a Lincoln Quicklub® Lubrication System, free flow of lubricant from the pump through the transmission system and the bearings is necessary. If any portion of this transmission system (a divider valve, line fitting or any bearing) does not freely accept and pass its portion of the lubricant a blockage has occurred. This blockage will cause a higher than normal pumping pressure to be developed by the pump.
Use Filtered Lubricant Only. Note: Dirt and foreign material are the worst enemies of any lubricating system. Procedure 1. Use a manual pump with a gauge. Fill the pump with clean, filtered lubricant common to the system. Connect the manual pump into the inlet of the primary divider valve and slowly operate pump. If system will not cycle freely below 1,500 PSI, see Step 2. 2.
SSV-D Metering Adjustment Screw Outputs and Identification Part Number 303-16118-1 303-16119-1 303-16120-1 303-16121-1 303-16122-1 303-16123-1 303-16124-1 303-16125-1 303-16126-1 303-16127-1 Output per Stroke 0.0049 in3 (0.08 cm3) 0.0085 in3 (0.14 cm3) 0.012 in3 (0.2 cm3) 0.018 in3 (0.3 cm3) 0.024 in3 (0.4 cm3) 0.037 in3 (0.6 cm3) 0.049 in3 (0.8 cm3) 0.061 in3 (1.0 cm3) 0.085 in3 (1.4 cm3) 0.110 in3 (1.
